Progress on the Corrado

[rollercoasterracer]

After years of being in need of paint, I finally bit the bullet after it was hit while in storage. My buddy from Denmark took on the project for me, and is doing all the body work, after he went through everything wiring-wise to get everything working again. I'm going to talk to him tomorrow about doing a TDI swap, seeing as it's going to be a daily driver for the wife, and she commutes kinda far (and gas prices are getting insane).


Not all the newest ones are up there, but he tries to update it between his projects and computer work.
Here's a couple pics of some of his other ones he's had a hand in (he's a huge Scirocco fan). He's turned out a lot of really good stuff, and is anal about everything he does, so I know it's going to be done right.

[rollercoasterracer]

Not a lot of mods are happening at this time, just fender rolling, shaving the rear emblems and badges, wiper/squirter, front squirters, side rub strips, and corner markers on the front bumper, antenna, and license plate holes. Everything else is just getting banged out and smoothed over (dents, dings, etc).

[rollercoasterracer]

Well, might as well just keep this one updated instead of making a new thread. This car has gone through a lot with me, so me and the wife decided to keep it for a while. Plus, it's one of our favorite VWs; and I already own it, so why get rid of it?

Things got interesting the first day I bought it; heater core blew. Not long after that, took it on a cross country trip from WA to GA:

http://forums.vwvortex.com/showthrea...rado!-(made-it!)

I drove it down there for a few months before moving to Alaska and leaving the car in storage for 3yrs. When I came back to pick it up, it had somehow been t-boned:

http://forums.vwvortex.com/showthrea...led-my-Corrado...

Took it on another cross country trip from GA back up to WA. Made it most of the way on it's own power:

http://forums.vwvortex.com/showthrea...(pic-intensive)

I dropped it off at my friend's place to get a lot of issues worked out with it as well as work out all of the body work:



























A couple months later, decided to swing a deal with a friend and trade the Lysholm engine out of it for a '79 Rabbit diesel with a rebuilt (less than 1k) 1.6D with a diesel 5spd:









Now she's sitting like this:





Just received delivery of an ALH/02J swap with the Kerma PD150 kit from MKIII and Sons (thanks!):







It's going to be a couple weeks before my buddy is able to get started on it. Doing complete swap so everything works (even Mk4 cluster). Also doing ABS delete, installing the Wilwood kit, re-painting and cleaning up the engine bay, etc. This car is going to be daily driver status, not show, so it's being built for purpose (I know... I deleted the rear wiper and front squirters... that was when I was 50/50 on what the car was going to be used for).

[Markg813]

[rollercoasterracer]

Thanks!

And if anyone has any input, ideas, experience, etc. about an ALH/02J swap, feel free to chime in

[h00ters CEO]

ALH/02J swap,

The what?

[kjperry]

The what?

1.9L TDI

[h00ters CEO]

in a corrado?! Thats friggin awesome!

:subscribed:

[skaterazn]

Do you still want that turbo timer?

[GT TDI Golf]

Thanks!

And if anyone has any input, ideas, experience, etc. about an ALH/02J swap, feel free to chime in

Check with G60ing. He's done a couple TDI Corrado swaps one of which was an ALH. He's also on TDIclub.

[Rallye 1.8T]

I bought TDI PD 130 HP with 6 speed for my Corrado.

But no. That engine is now in mk3 chipped to 164 HP , it's fast , high mpg...

That sound and Corrado really don't go together


Sorry...

[rollercoasterracer]

in a corrado?! Thats friggin awesome!

:subscribed:

Thanks, man, I'm hoping it will turn out as planned!

Do you still want that turbo timer?

Turbo timer??

Check with G60ing. He's done a couple TDI Corrado swaps one of which was an ALH. He's also on TDIclub.

Yeah, I've gotten a bit of information from him, thanks!

I bought TDI PD 130 HP with 6 speed for my Corrado.

But no. That engine is now in mk3 chipped to 164 HP , it's fast , high mpg...

That sound and Corrado really don't go together


Sorry...

A Mk3 would be fun, too! I had a Syncro Swallowtail 20v planned, but we need more of a daily car, not a project. And seeing as we already have a reliable 1.6D, we figured we might as well put a TDI into the Corrado. My wife and I both drive a LOT! And after my B3 Syncro TDI wagon, I mised the MPGs, and figured why not combine power, Corrado, and good MPGs? haha

But I have heard that argument a lot... and I will admit, I'm going to miss the Lysholm whine. But, in the end, I think it's a logical choice. May not be for the purists though

[Rallye 1.8T]

MPG are great , that's the fact.

Only problem is sound...

[rollercoasterracer]

Went over there a couple days ago to discuss and plan out a few things. Hoping to tow the Corrado to his place next weekend so we can dive into it. He cleaned the engine up and started sorting through the wiring. I still haven't had time to breathe after work, so I haven't got much farther.

The one that came out:


The one that's going in:






A few pictures of some items hanging on my buddy's "Wall of Shame"




While we were going over a few things, we received a call from another friend at his shop up the road. He had made a mis-calculation while pulling out the engine/trans in his Corvette that caused him to be stuck with standing on the rear of the cherry picker for counter-balance. After we got to his place and took a few pictures and made fun of him, we helped.










Going to resurface the flywheel, replace the throw-out bearing, clutch, timing belt, idlers, tensioner, thermostat, and water pump. Is there anything else I should do for preventative maintenance while it's out and easy to get to?

[rollercoasterracer]

Towed the car to my buddy's house who's doing the swap yesterday.











What the Lysholm engine is going into (another C):




Decided to do an ABS delete, and clean up the wiring a tad bit in the engine bay. This is going to be cleaned up and re-painted as well.

[rollercoasterracer]

If anyone has a line on any of this stuff locally, or can do a package deal for shipping all of this, let me know!

http://forums.vwvortex.com/showthrea...ets-airbox-etc.

Mk3 or SLC K-frame
Passat (B3/B4)/SLC front crossmember
Mk3 ABA/TDI rear motor mount bracket
B4/Mk3 TDI front motor mount bracket
Mk2/SLC air-box
95ish SAAB 900 intake boot

[rollercoasterracer]

Just put our truck up for sale in order to pay for more parts!

http://forums.vwvortex.com/showthrea...2#post75597392

Headed over to do some werk on the Corrado tomorrow, I'll post more pics tomorrow :-) Just got my wisdom teeth pulled today though, so not sure what good I'm going to be other than photography... IF I make it over there.

[GT TDI Golf]

I'm not sure what's included in Kerma's 150hp kit (I'm guessing VNT17, PP520's, tune, and clutch kit maybe?) but I would also look into an Oldman TIP. I haven't used their tune but have one of their turbo's on my car. It's an 1856 that used to be called a Hammerhead SV and I think it's now called a K3A or something. May want to look at larger nozzles as well. I'm running PP502's but I'm about to step up to R520's. The 502's are great with stock turbo and up though. Also get more of a robust clutch than you think you need. Trust me on this. I'm putting the third one in when I decide to install my O2M swap. With just the 502's installed, no other mods, my factory clutch slipped. Did the VR clutch and then the turbo upgrade and the diff blew etc. Not sure if you're looking for a lot of power but since the motor's still out it may be easier to do this now. Also you can upgrade your intake manifold to the PD150 or your injector pump. If you're already doing the timing belt check out a cam upgrade as well. Lot's of stuff you can do and hey its only money right Good luck with it! I've thought about a TDI swap but agree with Rallye 1.8T, it just won't sound right. just the same.

[rollercoasterracer]

I was thinking about using this clutch:

http://www.kermatdi.com/servlet/-str...EEL-%09/Detail

What do you think?

Unfortunately, I don't have the monies for upgrades that aren't considered maintenance right now... and I'm only going to be able to drive it for a couple weeks before I leave. It's going to be the wife's car while I'm gone, and she hasn't driven anything with a decent amount of go; I'd rather not up the power from the get-go haha It's pretty much just going to be maintained the way it is from here on out (as of now..). When I get back from deployment, there's a couple other projects I'd like to throw money at

[GT TDI Golf]

That clutch kit should be fine. One thing to think about and ask Kerma is if it rattles at idle without the clutch pedal depressed. Mine rattles like hell and it's driven me nuts. It happens when you go with to light of a flywheel. Mine is 14lbs so maybe you won't have that issue. The TDI is a bit of a slug but really responds well to mods. Best thing about modifying it is as long as you keep your foot out of it it will still have great fuel mileage! I made it from Birmingham, AL to Las Vegas 18xx miles on 3 tanks of diesel and mine is FAR from stock. This was in my Golf though

[rollercoasterracer]

Nice! haha Yeah, I'm sticking with an OE flywheel, I will never have a L/W unless it's my strictly track car.

[rollercoasterracer]

Just picked up a complete ABS assembly (the brakes on mine went to manual power, hoping this will solve it!). Thanks, trip permit !

If this doesn't fix it, I'm deleting the ABS. It was too good of a deal to not try; cheaper and easier to keep it if this fixes it.

[rollercoasterracer]

Drove down to Portland today and picked up a complete K-frame from Flip-Side, thanks!

And got a call from Juan, saying he shipped out the engine mounts, brackets, and TD airbox. Thanks, ellocolindo !


Something I've been thinking about for a while now, but I'm very tempted today to put my Mk2 up for trade for a Mk3/Mk4/B3/B4/B5... we'll see what happens this week.

[rollercoasterracer]

oye... been doing nothing but laying on the couch and taking perks. Just got all my wisdom teeth pulled, so I'm still out for a bit. Ordering lots of needed parts though, so hopefully in a week or two we can really start doing werk.

[rollercoasterracer]

Got some progress done this weekend. Shaved the rear bracket to fit around the turbo. Mounted the engine for mock-up of everything to see where we need to cut the firewall/rain tray to feed things through to the cab and what not. Realized after about 30min of why it wasn't working that I have early style 02J cables, but a transmission that requires the later style cables... great. Still waiting on more money to order the TBK, clutch kit, t-stat, starter, late style 02J cables, SpoonFedTuning parts, etc... My buddy has been going through the wiring mess cutting out the unnecessary Mk4 parts.





My old engine in another Corrado; almost done.








no clearance what-soever...


useless... going to a remote oil filter kit with air-oil cooler

[rollercoasterracer]

No pictures right now, but just wanted to say thanks to Jeff at Techtonics Tuning for the hookup! Also to Paul and Charlie at Kerma TDI for dealing with my questions and the awesome parts! Still have a lot to do, but it is coming together... I don't think I'm going to be able to drive it before I deploy this month, but I'm looking forward to driving it when I come back!

[rollercoasterracer]

Well, time-line didn't quite work as planned haha My wife and my friends are going to finish it for me while I'm gone. I leave next week, and life got in the way of the progress of this lately. I won't have regular internet access or contact, so I probably won't be able to update this with pictures or even get any. I'll update in about 9months haha

[a_riot]

Curious about the repaint as I am wanting to do the same. What paint did you use? I assume its base/clearcoat? It looks really good in the pictures. Did you have it done somewhere in the PNW?

[rollercoasterracer]

No, it's actually just single stage PPG or Omni (I don't remember). Once the engine bay is cleaned up and all, it's getting dual stage with clear in order to protect it more with the heat and all. My buddy Lars in the Puget Sound area did all the body/paint work for me, and he does a really good job. He has a lot of projects under his belt haha If you're in the area and need some work done, PM me and I'll give you his contact info.

[red85GTi]

This forum needs more diesel Rado's like this one! My aaz was lame so I am going VRT but in due time I plan a very similar build. Probably not a PD150 but a TDI with a VNT17 and some other goodies. Great work man!

[rollercoasterracer]

Thanks! I'm hoping it will be fun..

[girdwood]

Thanks, Spoon Fed Tuning for the goodies... hoping it pulls the 'clean' look off better.

Just want to say thanks to Alex, Lars, Tyler, Matt, Dan, Charlie, and everyone else around the area that's helped me with this project (parts, labor, and other things). It's great to have good friends! I can't wait to see the pay-off!

I haven't had much contact with my buddies that are doing the work, but last I talked to him, it's coming along well (wiring nightmare). Still waiting on a few parts for the maintenance side of things. If all goes well, December it will be on the road! It sucks being deployed and not being able to work on it first hand anymore, but I know she's in good hands.

(I lost my password and email info, so I can no longer use that handle).

[girdwood]

She's alive! I was informed that it has been started up for the first time! There's still a lot of work left to do, but it was a nice stepping stone that proved progress. My buddy is trying to get it all finished before the end of this month in order to show it in a local car show... fingers crossed.

[girdwood]

My wife sent me a video of it on start-up and running! I'm getting anxious to drive it... They weren't able to complete it before PWL, but they are confident it will be done before I get home (end of November). The engine is back out, and they are re-doing the engine bay currently. Sounds like we're going to not run an intercooler right away, and I'll figure something out when I get home. There's still some odds and ends that need to be done, but nothing major. My wife is about to take delivery on her Mk4 GLI, too, and it needs a few things to make it a good daily, so that is going to be taking up some time as well.

I've also been browsing other cars... The Mk1 diesel just isn't cutting it as a daily, I need something either 1) with more 'smile' factor, or 2) more comfortable. I'm debating between 3 classifications: 1) a truck (old school, mainly Chevy, '55-'56) for a temporary hauler that I can build up over the years into a hot-rod, 2) more comfortable daily driver (mainly Passats, but maybe a Golf/Jetta), and 3) something that is semi-daily driveable that I can slowly turn into the "weekend-warrior" to play with at the auto-x track and what not (really leaning towards a Mk1 GTI).

[girdwood]

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